Engine rebuild with no former experience........

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03 Mar 2021 20:32 #270200 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The first job was to sit the torque converter into the transmission, it took a while to get the tangs on the rotor to seat properly into the pump.

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According to the manual this looks correct, ~4mm of the ring gear showing.

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Getting ready to fit to the engine, I decided to weigh down the back of the engine as it was almost balanced.

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Lifted with the engine crane, this must be very tricky to do from under the engine with the car on stands.

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It bolted together without a hitch.

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Transmission mount fitted.

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Next this lot.

Trans oil cooler lines.
Trans dip stick and tube.
Trans shift point rod.
Trans vacuum modulator pipe.

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Oil cooler lines fitted first.

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Then the rest.

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The shift point rod initially didn't go where it was supposed to so had to do a bit of bending to get it to fit. I think it was damaged before I bought this engine ten years ago and has always given me problems. It now connects up here to the throttle linkage.

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Cheers
Jim

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03 Mar 2021 20:32 #270201 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
This single 12.9 bolt came through, so can swap out the cap head I fitted when refurbing the steering box. I couldn't find one self coloured hex bolt in this size round here so bought from china for £1 and free shipping. How does that work?

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Cheers
Jim

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04 Mar 2021 00:21 #270211 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

the regulations of the Universal Postal Union consider China still as a developing country and these countries have to pay very low rates to get their shipments transported to the destination. In fact lower than the actual costs meaning that the other members of the UPU subsidize Chinas shipments. These led to displeasure in some countries and subsequently to a veeeery gradual increase of the cost for China but it is still dead cheap to send items from China.

Regards,
Lutz
Nur wer für den Augenblick lebt, lebt für die Zukunft.
Heinrich von Kleist
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04 Mar 2021 20:06 - 04 Mar 2021 20:09 #270268 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The first job today was to fit the flex plate bolts.

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Then the starter motor....

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.... and earth strap.

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Then removed the idler arm bush, pretty tight.

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It is not metalastic bush, more like a poly bush. The old one was still in good condition but it will not be this easy to change ever again.

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Does anyone know if replacement front brake lines come preformed or are supplied as straight lengths? I would like to replace these and it would be good to have OEM ones.

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Finally a garage tidy up as the engine and engine bay prep work work is now complete, just waiting for warmer weather so I can get the engine bay painted, It could easily be a month before I can do that.

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Cheers
Jim

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Last edit: 04 Mar 2021 20:09 by Racediagnostics.
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05 Mar 2021 21:46 #270352 by makonp
Replied by makonp on topic Engine rebuild with no former experience........
Hi
the brake lines from aftermarket sources are not preformed, you have to bend them by yourself. I do not know if original brake lines come preformed.

Hope it helps and congrats to your job.

best wishes Matthias
Gruss aus dem Norden

Matthias
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07 Mar 2021 17:46 #270512 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I've been getting garage withdrawal symptoms so went back in today. In the middle of last year I noticed that the driver door lock was completely frozen. The key could be inserted but there was no way for it to be turned, it felt like it had been glued in place. I assume this is due to years of accumulated dirt, non use during the restoration and the remote central locking I now have fitted. Today it was time for a closer look.

First I removed the door handle.

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Then these parts from the inner end of the cylinder. 

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With the key in place to hold the cylinder parts captive, in theory the cylinder should just slide of of the handle, but in my case, I put the screw back in a bit and tapped with a light hammer to break it free.

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Into "plus gas" for cleaning.

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The barrel was also full of crud.

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Cleaned out with a pick, pipe cleaners and brake cleaner.

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The cylinder cleaned up and freed off pretty well.

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Rinsed and dried off with brake cleaner.

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Back together and working perfectly. Any suggestions on the best dry lubricant to use?

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Cheers
Jim

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07 Mar 2021 18:23 #270516 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

I use Lock-Ease for every lock.

Regards,
Lutz
Nur wer für den Augenblick lebt, lebt für die Zukunft.
Heinrich von Kleist
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08 Mar 2021 09:19 #270588 by KalliSL
Replied by KalliSL on topic Engine rebuild with no former experience........
I am using Ballistol for many puporses. Sonax SX90 Plus might be even better, or the Liqui Moly.
If you like to read a test - but it is in german :
www.motorradonline.de/zubehoer/9-multifu...alles-etwas-koenner/

Kalli
Gruss aus Bruchsal

Kalli
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08 Mar 2021 20:03 - 08 Mar 2021 20:07 #270668 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I got the lock fitted back into the door today and although the fey moves freely, it was still difficult to unlock the door due to the latch being gummed up.

So latch taken out.

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Cleaned in the ultrasonic cleaner.

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Re-greased and fitted and now works perfectly. I will clean up the lock and latch on the passenger door once the car is mobile again.

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One job always leads to another. The screw that holds the internal door handle in place stripped out when being replaced, it screws into a weak zinc casting.

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Drilled it out.

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Tapped.


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Helicoil fitted and job done.

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Cheers
Jim

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Last edit: 08 Mar 2021 20:07 by Racediagnostics.
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09 Mar 2021 20:37 #270776 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Time to make up new brake lines, I had some cunifer left over which is easy to bend by hand.

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Small ones are easy.

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Longer ones are a bit of a pain, I make the first couple of bends then tape the new line to the old one. That helps with the bend directions.

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I need more tube for the last line.

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Next I tried a paint trial on the back of the new bulkhead heat pad, the left square is two coats of plastic primer, the middle is two coats of plastic primer then two coats of high temp silver, the right is just two coats of high temp silver. Tomorrow I will try a scratch and bend test.

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Idler arm primed with acid etch.

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New lock/seal nut fitted to the steering box.

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The engine mounts sit on these two pads, in citric acid for de-rusting.....

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..... then paint stripped off. I also welded up one of the subframe mount captive nuts as I was worried about it breaking free. I will have to re-plate it.

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I don't really remember this bracket being used for anything so won't refit it. Does anyone have a close up showing what it is used for?

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Cheers
Jim

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10 Mar 2021 20:35 - 10 Mar 2021 20:37 #270878 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I am glad I tried a paint test on the bulkhead insulation pad. First I bent the paint sample then scratched it with my finger nail.

Just the "plastic primer" patch. FAIL!

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"Plastic primer" then silver paint. FAIL

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Just the paint with no primer. The paint could eventually be scraped off but no cracking or delamination.

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I had some other primer so decided to give that a try, so made up two new test areas, I will test these tomorrow.

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Next I primed the subframe pads.

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Then pulled out the old throttle link grommet.

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Fitted.

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Next I made up some epoxy primer to paint the seams in the engine bay for some extra protection. Once dry I will also add tiger seal.

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Last, I added a bit of green tinter to the left over epoxy, I can't add too much to get to the correct green without being worried about the integrity of the epoxy so the colour is a compromise. At least the back and front brake pipes will now match.

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Cheers
Jim

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Last edit: 10 Mar 2021 20:37 by Racediagnostics.
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11 Mar 2021 18:17 - 11 Mar 2021 18:50 #270995 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The experiment with the alternative primer was better, the primer was more scratch resistant and the patch with both primer and paint stood up to bending and scratching better than all of yesterdays options.

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Good news, but as expected the 1k silver paint is still susceptible to being easily marked, not good.

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So today I ordered up some 2k satin silver and will try that in a few days.

Next, seam sealer.

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Then removed the bumper and lower grill.

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Conservatory starting to fill up. again.

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Still too cold here for at least the next two weeks to paint the engine bay.

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Cheers
Jim

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Last edit: 11 Mar 2021 18:50 by Racediagnostics.
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12 Mar 2021 18:19 - 12 Mar 2021 18:23 #271095 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
It was only 3 or 4 degC here today, more snow, sleet, hail and windy so didn't make it into the garage, took a day off, but did get a few deliveries.

More cunifer for the last brake pipe, a straightening tool would be good but I may never do this again.

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This 2k silver arrived for the bulkhead insulation pad. I think 2k paint rather than 1k will be much better in the long run.

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The replacement front subframe nut (one was a bit bent), having one of these come loose would be a nightmare.

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This is the replacement idler arm bush from Mercedes, only marginally better quality than the Febi one (but 5x the price), you can see the old one was chrome plated, the new one is not but is smoother than the Febi one.

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I have no idea what this coating is but will replace it with passivated zinc. The supplied bolt id a 10.9 strength but the nut is only 8, seems odd.

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Cheers
Jim

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Last edit: 12 Mar 2021 18:23 by Racediagnostics.

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13 Mar 2021 16:25 #271173 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I made up the final brake pipe today.

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Trial fit to ensure a no problems later.

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Ready for paint, definitely the trickiest shape brake pipe I have ever made up.

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Cheers
Jim

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15 Mar 2021 23:48 #271366 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
10 hours in the garage today, a lot of cleaning and prep work.

I lifted the car off the subframe.

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Dragged out of the way.

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Then lots of cleaning and masking.

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It was filthy in here, I thought there was a bitumen liner/heat shield, it turned out to be 40 years of oil and dirt!

After cleaning.

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Jim

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16 Mar 2021 08:55 #271373 by markus1971
Replied by markus1971 on topic Engine rebuild with no former experience........
Hello Jim,

a lot of work ...10 hours (days) preparation for 10 minutes painting, it ´s always the same 
[img


One question, I also painted a small section of the engine bay, also with 2 K metalic  paint. I think originally the engine bay is only painted matt, no clear coat. I did it with clear coat, it looks too shiny...How are you going to paint the engine bay? Only with base coat and hardener oder additionally with clearcoat?
I will add a picture later...

best regards
Markus

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16 Mar 2021 12:52 #271394 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Markus, I will use base coat and clear, I am not too worried about originality, I prefer a nice looking easy clean surface.

Warming up the paint.

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Masking complete.

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Epoxy on by my target time of 11 in the morning.

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Cheers
Jim

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16 Mar 2021 21:08 - 16 Mar 2021 21:09 #271447 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
It reached the critical temperature!

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Basecoat.

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The clearcoat mist.

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Once the mist had cleared.

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A couple of hours later I removed the masking. These areas have never seen base coat before.

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Looking better than I could have expected.

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I feel like this is a major milestone and has been very stressful, I am very glad its over.
Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 16 Mar 2021 21:09 by Racediagnostics.
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16 Mar 2021 22:15 #271458 by mike 560
Replied by mike 560 on topic Engine rebuild with no former experience........
Hallo Jim

Very nice,thanks for the lot of picture.

Mike

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17 Mar 2021 07:58 #271461 by wusel-53
Replied by wusel-53 on topic Engine rebuild with no former experience........
Hi Jim,
I love your thread. It's amazing
[img

At the end, you have to write an workshop-report  :-)

Thanks a lot
Viele Grüße

Thorsten

Man lernt nie aus
380SL (US-Version, Bj.84), Eura-Wohnmobil und ein ebike :-)
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17 Mar 2021 20:40 #271555 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
More painting today.

Bulkhead insulation pad primed.

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Then painted with 2k satin solid silver.

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Catch up on these parts.

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Then the final brake pipe.

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First two parts (tiny clips) fitted back in the car.

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Cheers
Jim

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19 Mar 2021 21:39 #271691 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
In the end I decided to go for a black brake booster rather than silver, so a quick blow over with primer.

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Then 2k black.

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Time to have a look behind these baffles in the CAM covers.

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The rivets were easy to remove with this.

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Pretty bad in there, I'm glad I removed it.

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Cleaned up, I will need to drill and tap for small bolts or "hammer rivets", any thoughts on which to use?

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Getting ready to glue on the new insulation pad.

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[

Glued on in 5 sections, this was the last part to go on.

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All done.

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Cheers
Jim

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21 Mar 2021 18:54 - 21 Mar 2021 18:57 #271809 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Wiring and brake pipes back in.

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Cheers
Jim

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Last edit: 21 Mar 2021 18:57 by Racediagnostics.
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22 Mar 2021 18:04 - 22 Mar 2021 20:29 #271895 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Heat shields and PS hose/pipe fitted.

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PS box and brake booster fitted.

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Getting to the brake booster bolts is a PITA.

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Last job of the day was to go and get my Covid vaccination. I've got a holiday booked to Austria at the end of June but am not confident it is going to work out.

Front subframe back in tomorrow if I'm feeling OK. My wife felt ill for 24 hours after her vaccination.
Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 22 Mar 2021 20:29 by Racediagnostics.
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22 Mar 2021 21:06 #271905 by Dr-DJet
Replied by Dr-DJet on topic Engine rebuild with no former experience........
H Jim,

that looks brilliant and we envy you! However did you not mount brake booster, power steering and other parts on wrong side?
[img
Ignition seems to be correctly mounted.

Just kidding of course. Looks really great!
Viele Schraubergrüße - best regards, Volker, Admin und Betreiber
Fast alles zu Zündung und Jetronic auf jetronic.org
Workshops D-Jetronic 28.6.(F),20.9.(ER), K-Jetronic 31.5.(ER),23.8.(F)

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23 Mar 2021 10:06 #271918 by KalliSL
Replied by KalliSL on topic Engine rebuild with no former experience........
And when you have finished your job ....... before you get bored - I´ll give you my 300SL for the next winter and you can do the same, and I won`t charge you a single cent ! 
[img
Gruss aus Bruchsal

Kalli
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23 Mar 2021 18:33 #271960 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Well I had a post covid vaccine "hangover" this morning so didn't make it out till after 3.

I pulled the subframe back into place, that was actually a lot of effort as it wouldn't roll to where it was needed.

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Bolted back in place.

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Tomorrow I will roll the car out of the garage and move the lift to give access for the engine crane.

Does anyone know what this clip is used for, I don't remember anything being clipped into it. It was pushed on just ahead of the brake pipe and behind the engine shock absorber mount.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
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23 Mar 2021 19:00 #271966 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Hi,
i think it could be from the  main wire from the Battery to the Starter/Generator.

 
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Grüße aus Hamburg.

Frank

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23 Mar 2021 20:06 #271975 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Frank, I don't think so, my harness has two clips on it which attach to the engine block. Perhaps one is missing from the harness?
Cheers
Jim

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1979 450SL - 2002 XK8 4.2

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24 Mar 2021 09:28 #272004 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Hi Jim,
if i remeber correctly, there was such a clip on the heat-shield underneath the battery.
But i don't see it in WebParts....

 
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Grüße aus Hamburg.

Frank

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